Washable Multi-Component Magnetic Floor Mat

ABSTRACT

This invention relates to a washable multi-component magnetic floor mat. The floor mat contains a textile component and a base component. The textile component and the base component are attached to one another by magnetic attraction. The magnetic attraction is provided by incorporation of magnetic particles in both the textile and base components. The textile component is designed to be soiled, washed, and re-used, thereby providing ideal end-use applications in areas such as building entryways. The present invention eliminates the need to wash the base component of the floor mat which results in environmental, cost and labor conservation. Alignment and deployment of the textile component with the base component in an efficient manner is also described herein.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/212,350, entitled “Washable Multi-ComponentMagnetic Floor Mat” which was filed on Jul. 18, 2016, which is anon-provisional of and claims priority to U.S. Provisional PatentApplication No. 62/201,148, entitled “Washable Multi-Component MagneticFloor Mat” which was filed on Aug. 5, 2015, all of which are entirelyincorporated by reference herein.

TECHNICAL FIELD

This invention relates to a washable multi-component magnetic floor mat.The floor mat contains a textile component and a base component. Thetextile component and the base component are attached to one another bymagnetic attraction. The magnetic attraction is provided byincorporation of magnetic particles in both the textile and basecomponents. The textile component is designed to be soiled, washed, andre-used, thereby providing ideal end-use applications in areas such asbuilding entryways. The present invention eliminates the need to washthe base component of the floor mat which results in environmental, costand labor conservation. Alignment and deployment of the textilecomponent with the base component in an efficient manner is alsodescribed herein.

BACKGROUND

High traffic areas, such as entrances to buildings, restrooms, breakareas, etc., typically have the highest floorcovering soiling issue.Currently, washable one-piece mats having a pile surface are found inthese locations. The washable multi-component magnetic floor mat of thepresent invention is designed to replace these one-piece floor mats. Theuse of washable multi-component floor mats in high traffic, highlysoiled areas is pragmatic because the soiled textile component may beeasily removed, laundered, and re-installed. The need to launder thebase portion of the floor mat is eliminated. The reduction in weight andbulk from one-piece mats to the textile component of the multi-componentmat provides significant savings in water and energy for the launderingfacilities and in labor for the service people that transport andinstall the floor mats.

Furthermore, because the attachment mechanisms can utilize a high amountof force to hold the top and bottom components of the floor mattogether, the initial alignment and deployment of the top textilecomponent onto the base component can present challenges. This problemis exaggerated by the large surface area of the two components that arein contact with one another. In this regard, even if the adherence forceper unit area is low, the large surface area means that the totalresistance to sliding and movement can be very high making realignmentof the components very difficult. If not corrected, mis-alignment of thetextile component with the base component may create trip hazards withinthe floor mat and may be aesthetically not pleasing.

The present invention overcomes these challenges via the use ofalignment and deployment techniques that rely upon temporary reductionin surface area of the textile and/or base component and/or temporaryreduction in adherence force between the textile and base components.Thus, the washable multi-component magnetic floor mats of the presentinvention are an improvement over one-piece floor mats of the prior art.

BRIEF SUMMARY

In one aspect, the invention relates to a multi-component floor matcomprising: (a) a textile component comprising (i) a first layer oftufted pile carpet formed by tufting face yarns through a primarybacking layer and (ii) a second layer of vulcanized rubber material thatcontains magnetic particles; (b) a base component comprised of (i)vulcanized rubber that contains magnetic particles or (ii) vulcanizedrubber having a magnetic coating applied thereto; and wherein thetextile component and the base component are releasably attachable toone another via magnetic attraction.

In another aspect, the invention relates to a multi-component floor matcomprising: (a) a textile component comprising (i) tufted pile carpetwherein face yarns are tufted through a primary backing layer and (ii) amagnetic coating wherein the magnetic coating is comprised of magneticparticles and a binder material; (b) a base component comprised of (i)vulcanized rubber that contains magnetic particles or (ii) vulcanizedrubber having a magnetic coating applied thereto; wherein the textilecomponent and the base component are releasably attachable to oneanother via magnetic attraction.

In another aspect, the invention relates to a multi-component floor matcomprising: (a) a textile component comprising (i) a first layer oftufted pile carpet wherein face yarns are tufted through a primarybacking layer and (ii) a second layer of vulcanized rubber material thatcontains magnetic particles or a second layer of magnetic coating; (b) abase component comprised of (i) vulcanized rubber and magnetic particlesor vulcanized rubber and a magnetic coating and (ii) electronic sensors;wherein the textile component and the base component are releasablyattachable to one another via magnetic attraction.

In a further aspect, the invention relates to a process for cleaning amulti-component floor mat, said process comprising the steps of: (a)providing the multi-component floor mat of the present invention; (b)removing the textile component from the base component; (c) launderingthe textile component in an industrial, commercial, or residentialwashing machine; and (d) re-installing the textile component on orwithin the base component.

In another aspect, the invention relates to a process for making amulti-component floor mat, said process comprising the steps of: (a)tufting face yarns into a primary backing material to form a tufted pilecarpet; (b) optionally, printing the tufted pile carpet; (c) providing alayer of unvulcanized rubber that contains magnetic particles; (d)adhering the tufted pile carpet to the layer of magneticparticle-containing unvulcanized rubber via a rubber vulcanizationprocess to form a washable textile component having a vulcanized rubberbacking; (e) cutting the textile component into a desired shape andsize; (f) providing a base component comprised of (i) vulcanized rubberand magnetic particles or (ii) vulcanized rubber and a magnetic coating;and (g) attaching the textile component to the base component viamagnetic attraction.

In a further aspect, the invention relates to a process for making amulti-component floor mat, said process comprising the steps of: (a)tufting face yarns into a primary backing material to form a tufted pilecarpet; (b) optionally, printing the tufted pile carpet; (c) providing amagnetic coating comprised of magnetic particles and a binder material;(d) adhering the magnetic coating to the tufted pile carpet to form awashable textile component; (e) cutting the textile component into adesired shape and size; (f) providing a base component comprised of (i)vulcanized rubber and magnetic particles or (ii) vulcanized rubber and amagnetic coating; and (g) attaching the textile component to the basecomponent via magnetic attraction.

In yet a further embodiment, the invention relates to a method forinstallation of a multi-component floor mat comprising the followingsteps: (a) providing a base component, wherein the base componentcontains at least one attachment means; (b) providing a textilecomponent, wherein the textile component is comprised of tufted pilecarpet and contains at least one attachment means that works incorresponding relationship with the at least one attachment means ofstep “a,” and wherein the base component and the textile component arereleasably attachable to one another via the at least one attachmentmeans; (c) aligning the textile component with the base component,wherein the step of aligning is accomplished via the use of at least onealignment or deployment mechanism; and (d) deploying the textilecomponent onto the base component.

In yet another aspect, this invention relates to a multi-component floormat comprising: (a) a textile component comprising (i) a first layer oftufted pile carpet formed by tufting face yarns through a primarybacking layer and (ii) a second layer of vulcanized rubber material thatcontains magnetic particles; and (b) a base component comprised of (i)materials selected from the group consisting of concrete,cellulose-containing materials, metal, thermoplastic materials,thermoset materials, and combinations thereof, and (ii) magneticparticles or a magnetic coating applied to the base component; andwherein the textile component and the base component are releasablyattachable to one another via magnetic attraction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an expanded view of the textile component of the floor mat.

FIG. 1B is an expanded view of another embodiment of the textilecomponent of the floor mat.

FIG. 2A is a top perspective view of one embodiment of the basecomponent of the floor mat.

FIG. 2B is a top perspective view of the multi-component floor mat withthe textile component partially pulled back from the recessed area of abase component.

FIG. 2C is a top perspective view of the multi-component floor mat withthe textile component and a flat (no recessed area) base component.

FIG. 2D is a top perspective view of the multi-component floor mat withthe textile component partially pulled back from the flat (no recessedarea) base component.

FIG. 3A is an expanded planar view of a rubber gripping pattern presenton the back of the base component of the floor mat.

FIG. 3B is an expanded angle view of a rubber gripping pattern presenton the back of the base component of the floor mat.

FIG. 4 is a schematic diagram of one embodiment of the manufacturingprocess of the multi-component floor mat.

FIG. 5 is a schematic diagram illustrating the magnetic alignmentproperties of the magnetic particles of the present invention.

DETAILED DESCRIPTION

The present invention described herein is a washable multi-componentmagnetic floor mat. The mat is comprised of a textile component and abase component. The textile component and the base component areattached to one another via magnet attraction.

The base component of the floor mat may be partially or wholly coveredwith a textile component. Typically, the textile component will belighter in weight than the base component. Inversely, the base componentwill weigh more than the textile component.

As shown in FIG. 1A, textile component 100 may be comprised of tuftedpile carpet 125. Tufted pile carpet 125 is comprised of primary backinglayer 117 and face yarns 115. The primary backing layer 117 is typicallyincluded in the tufted pile carpet to give stability to the face yarns.The materials comprising face yarns 115 and primary backing layer 117may independently be selected from synthetic fiber, natural fiber,man-made fiber using natural constituents, inorganic fiber, glass fiber,and a blend of any of the foregoing. By way of example only, syntheticfibers may include polyester, acrylic, polyamide, polyolefin,polyaramid, polyurethane, or blends thereof. More specifically,polyester may include polyethylene terephthalate, polytrimethyleneterephthalate, polybutylene terephthalate, polylactic acid, orcombinations thereof. Polyamide may include nylon 6, nylon 6,6, orcombinations thereof. Polyolefin may include polypropylene,polyethylene, or combinations thereof. Polyaramid may includepoly-p-phenyleneteraphthalamide (i.e., Kevlar®),poly-m-phenyleneteraphthalamide (i.e., Nomex®), or combinations thereof.Exemplary natural fibers include wool, cotton, linen, ramie, jute, flax,silk, hemp, or blends thereof. Exemplary man-made materials usingnatural constituents include regenerated cellulose (i.e., rayon),lyocell, or blends thereof.

The material comprising face yarns 115 and primary backing layer 117 maybe formed from staple fiber, filament fiber, slit film fiber, orcombinations thereof. The fiber may be exposed to one or more texturingprocesses. The fiber may then be spun or otherwise combined into yarns,for example, by ring spinning, open-end spinning, air jet spinning,vortex spinning, or combinations thereof. Accordingly, the materialcomprising face yarns 115 will generally be comprised of interlacedfibers, interlaced yarns, loops, or combinations thereof.

The material comprising face yarns 115 and primary backing layer 117 maybe comprised of fibers or yarns of any size, including microdenierfibers or yarns (fibers or yarns having less than one denier perfilament). The fibers or yarns may have deniers that range from lessthan about 0.1 denier per filament to about 2000 denier per filament or,more preferably, from less than about 1 denier per filament to about 500denier per filament.

Furthermore, the material comprising face yarns 115 and primary backinglayer 117 may be partially or wholly comprised of multi-component orbi-component fibers or yarns in various configurations such as, forexample, islands-in-the-sea, core and sheath, side-by-side, or pieconfigurations. Depending on the configuration of the bi-component ormulti-component fibers or yarns, the fibers or yarns may be splittablealong their length by chemical or mechanical action.

Additionally, face yarns 115 and primary backing layer 117 may includeadditives coextruded therein, may be precoated with any number ofdifferent materials, including those listed in greater detail below,and/or may be dyed or colored to provide other aesthetic features forthe end user with any type of colorant, such as, for example,poly(oxyalkylenated) colorants, as well as pigments, dyes, tints, andthe like. Other additives may also be present on and/or within thetarget fiber or yarn, including antistatic agents, brighteningcompounds, nucleating agents, antioxidants, UV stabilizers, fillers,permanent press finishes, softeners, lubricants, curing accelerators,and the like.

The face yarns 115 may be dyed or undyed. If the face yarns 115 aredyed, they may be solution dyed. The weight of the face yarn, pileheight, and density will vary depending on the desired aesthetics andperformance requirements of the end-use for the floor mat. In FIG. 1A,face yarns 115 are illustrated in a loop pile construction. Looking toFIG. 1B, textile component 100 is shown with face yarns 115 in a cutpile construction. Of course, it is to be understood that face yarnconstructions including combinations of loop pile and cut pile maylikewise be used.

The primary backing layer 117 can be any suitable primary backingmaterial. The primary backing layer 117 may be comprised of a woven,nonwoven or knitted material, or combinations thereof. The generalpurpose of primary backing layer 117 is to support the tufts of faceyarns 115. In one aspect, primary backing layer 117 is a nonwovenpolyester spunbond material. One commercially available example of thepolyester spunbond material is Lutradur® from Freudenberg Nonwovens ofWeinheim, Germany. In another aspect, flat woven polyester tapes, suchas Isis™ from Propex of Chattanooga, Tenn., may be utilized. Also,Colback® nonwoven backing material may also be suitable for use. Ifneeded, a primary backing layer made of a woven tape with either staplefibers or nonwoven fabrics affixed can be used. Also, stitch bonded andknitted polyester fabrics may be used.

The tufted pile carpet 125 that includes face yarns tufted into aprimary backing layer may be heat stabilized to prevent dimensionalchanges from occurring in the finished mat. The heat stabilizing or heatsetting process typically involves applying heat to the material that isabove the glass transition temperature, but below the meltingtemperature of the components. The heat allows the polymer components torelease internal tensions and allows improvement in the internalstructural order of the polymer chains. The heat stabilizing process canbe carried out under tension or in a relaxed state. The tufted pilecarpet is sometimes also stabilized to allow for the yarn and primarybacking to shrink prior to the mat manufacturing process.

In one aspect of the present invention, the tufted pile carpet iscomprised of yarn tufted into fabric, which is then injection or fluiddyed, and then bonded with a rubber layer or washable latex backing. Thecarpet yarn may be selected from nylon 6; nylon 6,6; polyester; andpolypropylene fiber. The yarn is tufted into a woven or nonwovensubstrate. The yarn can be of any pile height and weight necessary tosupport printing. The tufted pile carpet may be printed using any printprocess. In one aspect, injection dyeing may be utilized to print thetufted pile carpet.

Printing inks will contain at least one dye. Dyes may be selected fromacid dyes, direct dyes, reactive dyes, cationic dyes, disperse dyes, andmixtures thereof. Acid dyes include azo, anthraquinone, triphenylmethane and xanthine types. Direct dyes include azo, stilbene, thiazole,dioxsazine and phthalocyanine types. Reactive dyes include azo,anthraquinone and phthalocyanine types. Cationic dyes include thiazole,methane, cyanine, quinolone, xanthene, azine, and triaryl methine.Disperse dyes include azo, anthraquinone, nitrodiphenylamine, naphthaimide, naphthoquinone imide and methane, triarylmethine and quinolinetypes.

As is known in the textile printing art, specific dye selection dependsupon the type of fiber and/or fibers comprising the washable textilecomponent that is being printed. For example, in general, a disperse dyemay be used to print polyester fibers. Alternatively, for materials madefrom cationic dyeable polyester fiber, cationic dyes may be used.

The printing process of the present invention uses a jet dyeing machine,or a digital printing machine, to place printing ink on the surface ofthe mat in predetermined locations. One suitable and commerciallyavailable digital printing machine is the Millitron® digital printingmachine, available from Milliken & Company of Spartanburg, S.C. TheMillitron® machine uses an array of jets with continuous streams of dyeliquor that can be deflected by a controlled air jet. The array of jets,or gun bars, is typically stationary. Another suitable and commerciallyavailable digital printing machine is the Chromojet® carpet printingmachine, available from Zimmer Machinery Corporation of Spartanburg,S.C. In one aspect, a tufted carpet made according to the processesdisclosed in U.S. Pat. No. 7,678,159 and U.S. Pat. No. 7,846,214, bothto Weiner, may be printed with a jet dyeing apparatus as described andexemplified herein.

Viscosity modifiers may be included in the printing ink compositions.Suitable viscosity modifiers that may be utilized include known naturalwater-soluble polymers such as polysaccharides, such as starchsubstances derived from corn and wheat, gum arabic, locust bean gum,tragacanth gum, guar gum, guar flour, polygalactomannan gum, xanthan,alginates, and a tamarind seed; protein substances such as gelatin andcasein; tannin substances; and lignin substances. Examples of thewater-soluble polymer further include synthetic polymers such as knownpolyvinyl alcohol compounds and polyethylene oxide compounds. Mixturesof the aforementioned viscosity modifiers may also be used. The polymerviscosity is measured at elevated temperatures when the polymer is inthe molten state. For example, viscosity may be measured in units ofcentipoise at elevated temperatures, using a Brookfield Thermosel unitfrom Brookfield Engineering Laboratories of Middleboro, Mass.Alternatively, polymer viscosity may be measured by using a parallelplate rheometer, such as made by Haake from Rheology Services ofVictoria Australia.

After printing, the tufted pile carpet may be vulcanized with a rubberbacking. The thickness of the rubber will be such that the height of thefinished textile component will be substantially the same height as thesurrounding base component when the base component is provided in a trayconfiguration. Once vulcanized, the textile component may be pre-shrunkby washing.

The textile component 100 further comprises a magnetic coating layer110. The magnetic coating layer 110 is present on the surface of thetextile component 100 that is opposite face yarns 115. Application ofmagnetic coating layer 110 to the tufted pile carpet 125 will bedescribed in greater detail below. The resulting textile component 100is wash durable and exhibits sufficient tuft lock for normal end-useapplications. In one alternative embodiment of the invention, thetextile component may be a disposable textile component that is removedand disposed of or recycled and then replaced with a new textilecomponent for attachment to the base component.

After the textile component has been made, it will be custom cut to fitinto the recessed area of the base component (for instances in which thebase component is in the form of a tray) or onto the base component (forinstances wherein the base component is substantiallyflat/trayless/without recessed area). The textile component may be cutusing a computer controlled cutting device, such as a Gerber machine. Itmay also be cut using a mechanical dye cutter, hot knife, straightblade, or rotary blade. In one aspect of the invention, the thickness ofthe textile component will be substantially the same as the depth of therecessed area when the base component is in the form of a tray.

FIG. 2A illustrates one embodiment of the base component of the floormat of the present invention. Referring to FIG. 2A, base component 200contains recessed area 260 surrounded by border 270. Border 270 slopesgradually upward from outer perimeter 280 to inner perimeter 290, tocreate recess 210 within base 200, corresponding to the recessed area of260. FIG. 2A illustrates that the recessed area 260 of base component200 possesses a certain amount of depth, thereby defining it as“recessed.” The depth of recessed area 260 is illustrated by 210.

The base component is a planar-shaped tray, which is sized toaccommodate the textile component. The base component may also include aborder surrounding the tray, whereby the border provides greaterdimensional stability to the tray, for example, because the border isthicker, i.e. greater in height relative to the floor. Additionally, theborder may be angled upward from its outer perimeter towards theinterior of the base component, so as to provide a recessed area wherethe tray is located, thereby creating a substantially level area betweenthe inner perimeter of the border and the textile component, when thetextile component overlays the tray. Additionally, the gradual inclinefrom the outer perimeter of the border to the inner perimeter of theborder minimizes tripping hazards and the recess created therebyprotects the edges of the textile component.

It can be understood that the base component may be subdivided into twoor more recessed trays, by extending a divider from one side of theborder to an opposite side of the border, substantially at the height ofthe inner perimeter. Accordingly, it would be possible to overlay two ormore textile components in the recesses created in the base component.

The base component, including the border, may be formed in a singlemolding process as a unitary article. Alternatively, the border and thetray may be molded separately and then bonded together in a secondoperation. The tray and border may be made of the same or differentmaterials. Examples of suitable compositions for forming the border andthe tray are elastomers, such as natural and synthetic rubber materials,thermoplastic and thermoset resins and metal. The rubber material may beselected from the group consisting of nitrile rubber, including densenitrile rubber, foam nitrile rubber, and mixtures thereof; polyvinylchloride rubber; ethylene propylene diene monomer (EPDM) rubber; vinylrubber; thermoplastic elastomer; and mixtures thereof. In one aspect,the base component is typically comprised of at least one rubbermaterial. The rubber material may contain from 0% to 40% of a recycledrubber material.

In one aspect, the base component may be formed into a tray shapeaccording to the following procedure. Rubber strips are placedoverlapping the edges of a metal plate. The metal plate is to be placedon top of a sheet rubber and covered on all 4 sides by strip rubber. Asthe mat is pressed, it will bond the sheet rubber to the strips. Thisprocess may be completed, for example, at a temperature of 370° F. and apressure of 36 psi. However, depending upon the rubber materialsselected, the temperature may be in the range from 200° F. to 500° F.and the pressure may be in the range from 10 psi to 50 psi. Using therecommend settings, the mat may be completely cured in 8 minutes. Afterthe rubber strips are bound to the rubber sheet, the metal plate isremoved leaving a void (i.e. a recessed area in the base component) inwhich to place the textile component. The textile component has theability to be inserted and removed from the base component multipletimes.

As seen in FIG. 2B, floor mat 1 is present in an arrangement whereintextile component 100 overlays recessed area 260 of base component 200.A corner of textile component 100 is turned back to further illustratehow the two components fit together within border 270.

As previously discussed herein, the base component of the floor mat maybe in the form a tray. However, in one alternative embodiment, the basecomponent of the floor mat may be flat and have no recessed area (i.e.the base component is trayless). A flat base component is manufacturedfrom a sheet of material, such as a rubber material, that has been cutin the desired shape and vulcanized.

FIG. 2C illustrates a multi-component floor mat 1 wherein textilecomponent 100 is combined with base component 200′ that is flat and hasno recessed area (i.e. trayless). FIG. 2D shows the multi-componentfloor mat 1 wherein both textile component 100 and base component 200′are assembled together.

FIGS. 3A and 3B illustrate one embodiment of the back surface of thebase component. The back surface of the base component is the surfacewhich lies on the floor and therefore has direct contact with thesurface of the floor. Various patterns and/or protrusions on the backsurface of the base component may be present so as to facilitate thebase component's adherence to the floor. As illustrated in FIGS. 3A and3B, protrusions 360 may be present on the back surface of base component300. The protrusions 360 may be present in a repeating pattern such thata three dimensional array of protrusions is formed having a uniformpattern.

The textile component and the base component are attached to one anotherby magnetic attraction. Magnetic attraction is achieved via applicationof a magnetic coating to the textile component and/or base component orvia incorporation of magnetic particles in a rubber-containing layerprior to vulcanization. Alternatively, magnetic attraction can beachieved using both methods such that a magnetic coating is applied tothe textile component and magnetic particles are included in thevulcanized rubber of the base component. The inverse arrangement is alsocontemplated.

The magnetic coating may be applied to the textile component and/or thebase component by several different manufacturing techniques. Exemplarycoating techniques include, without limitation, knife coating, padcoating, paint coating, spray application, roll-on-roll methods,troweling methods, extrusion coating, foam coating, pattern coating,print coating, lamination, and mixtures thereof.

FIG. 4 illustrates one embodiment of the manufacturing process of thetextile component of the present invention. The uncoated tufted pilecarpet 425 is fed to laminating belt 410. The belt moves through thecoating zone to lamination zone of the lamination press. A magneticcoating 420 is fed transversely to laminating belt 410. As magneticcoating 420 is fed to laminating belt 410, it passes under coating knife430. The coating knife 430 is adjusted so that the desired coatingthickness is achieved. For example, a magnetic coating thickness of 25mil may be desirable. After magnetic coating 420 passes under coatingknife 430, it comes into contact with tufted pile carpet 425. Themagnetic coating 420 and tufted pile carpet 425 then move transverselyto laminating press 440. Laminating press 440 is located abovelaminating belt 410. The laminating press 440 is lowered onto laminatingbelt 410, pressing tufted pile carpet 425 and magnetic coating 420together. The laminating press 440 is heated and therefore provides bothheat and pressure to the lamination process. Providing heat at thispoint of the lamination process further serves to cure any materials(e.g. binder materials) that may be contained within the magneticcoating. After a pre-determined amount of time, laminating press 440 islifted from laminating belt 410. The magnetic coating 420 is nowlaminated to tufted pile carpet 425 to form textile component 450. Inone aspect, the laminating press may be operated at a temperature in therange from 200° F. to 500° F. and at a pressure in the range from 10 psito 50 psi, or even at 300° F. and a pressure of 36 psi.

In instances wherein magnetic attraction is achieved by incorporatingmagnetic particles in a rubber-containing layer, the following proceduremay be utilized: (a) an unvulcanized rubber-containing material isprovided (such as nitrile, SBR, or EPDM rubber), (b) magnetic particlesare added to the unvulcanized rubber, (c) the particles are mixed withthe rubber, and (d) the mixture of step “c” is formed into a sheet andattached to the bottom of the textile component and/or represents thebase component. Mixing in step “c” may be achieved via a rubber mixingmill.

FIG. 5 is provided in order to illustrate some of the terms used hereinwith respect to various types of magnets and magnetization properties.In this application, magnetizable is defined to mean the particlespresent in the coating or vulcanized rubber layer are permanentlymagnetized or can be magnetized permanently using external magnets orelectromagnets. Once the particles are magnetized, they will keep theirmagnetic response permanently. The magnetizable behavior for generatingpermanent magnetism falls broadly under ferromagnets and ferrimagnets.Barium ferrites, strontium ferrites, neodymium and other rare earthmetal based alloys are non-limiting examples of materials that can beapplied in the magnetic coatings and/or vulcanized rubber layer.

As used herein, magnetically receptive is defined to mean the particlespresent in the coating and/or vulcanized rubber layer are onlymagnetically responsive in the presence of external magnets. Thecomponent that contains the magnetic particles is exposed to a magneticfield which aligns the dipoles of magnetic particles. Once the magneticfield is removed from the vicinity, the particles will becomenon-magnetic and the dipoles are no longer aligned. The magneticallyreceptive behavior or responsive magnetic behavior falls broadly underparamagnets or superparamagnets (particle size less than 50 nm).

This feature of materials being reversibly magnetic is shown in FIG. 5whereby the dipoles of the superparamagnetic or paramagnetic materialsare not aligned, but upon exposure to a magnet, the dipoles line up andpoint in the same direction thereby allowing the materials to exhibitmagnetic properties. Non-limiting examples of materials exhibiting thesefeatures include iron oxide, steel, iron, nickel, aluminum, or alloys ofany of the foregoing.

Further examples of magnetizable magnetic particles include BaFe₃O₄,SrFe₃O₄, NdFeB, AINiCo, CoSm and other rare earth metal based alloys,and mixtures thereof. Examples of magnetically receptive particlesinclude Fe₂O₃, Fe₃O₄, steel, iron particles, and mixtures thereof. Themagnetically receptive particles may be paramagnetic orsuperparamagnetic. The magnet particles are typically characterized asbeing non-degradable.

In one aspect of the invention, particle size of the magneticallyreceptive particles is in the range from 1 micron to 10 microns.Particle size of the magnetically receptive particles may be in therange from 10 nm to 50 nm for superparamagnetic materials. Particle sizeof the magnetically receptive particles is typically greater than 100 nmfor paramagnetic and/or ferromagnetic materials.

Magnetic attraction is typically exhibited at any loading of the abovemagnetic materials. However, the magnetic attraction increases as theloading of magnetic material increases. In one aspect of the invention,the magnetic field strength of the textile component to the basecomponent is greater than 50 gauss, more preferably greater than 100gauss, more preferably greater than 150 gauss, or even more preferablygreater than 200 gauss.

In one aspect, the magnetic material is present in the coatingcomposition in the range from 25% to 95% by weight of the coatingcomposition. In another aspect, magnetic particle loading may be presentin the magnetic coating applied to the textile component in the rangefrom 10% to 70% by weight of the textile component. The magneticparticle loading may be present in the magnetic coating applied to thebase component in the range from 10% to 90% by weight of the basecomponent.

The magnetically receptive particles may be present in the vulcanizedrubber layer of the textile component in a substantially uniformdistribution. In another aspect of the present invention, it iscontemplated that the magnetically receptive particles are present inthe rubber layer of the textile component in a substantially non-uniformdistribution. One example of a non-uniform distribution includes afunctionally graded particle distribution wherein the concentration ofparticles is reduced at the surface of the textile component intendedfor attachment to the base component. Alternatively, another example ofa non-uniform distribution includes a functionally graded particledistribution wherein the concentration of particles is increased at thesurface of the textile component intended for attachment to the basecomponent.

The magnetic attraction between the textile component and the basecomponent may be altered by manipulation of the surface area of one orboth of the textile and/or base components. The surfaces of one or bothof the components may be textured in such a way that surface area of thecomponent is increased. Such manipulation may allow for customization ofmagnetic attraction that is not directly affected by the amount ofmagnetic particles present in the floor mat.

For instance, a substantially smooth (less surface area) bottom surfaceof the textile component will generally result in greater magneticattraction to the top surface of the base component. In contrast, a lesssmooth (more surface area) bottom surface of the textile component (e.g.one having ripples or any other textured surface) will generally resultin less magnetic attraction to the top surface of the base component. Ofcourse, a reverse arrangement is also contemplated wherein the basecomponent contains a textured surface. Furthermore, both componentsurfaces may be textured in such a way that magnetic attraction ismanipulated to suit the end-use application of the inventive floor mat.

As discussed previously, the magnetic particles may be incorporated intothe floor mat of the present invention either by applying a magneticcoating to surface of the textile component or by including theparticles in the rubber material of the textile material and/or the basecomponent prior to vulcanization. When incorporation is via a magneticcoating, a binder material is generally included. Thus, the magneticcoating is typically comprised of at least one type of magneticparticles and at least one binder material.

The binder material is typically selected from a thermoplastic elastomermaterial and/or a thermoplastic vulcanite material. Examples includeurethane-containing materials, acrylate-containing materials,silicone-containing materials, and mixtures thereof. Barium ferrites,strontium ferrites, neodymium and other rare earth metal based alloyscan be mixed with the appropriate binder to be coated on the textileand/or base component.

In one aspect, the binder material will exhibit at least one of thefollowing properties: (a) a glass transition (T_(g)) temperature of lessthan 10° C.; (b) a Shore A hardness in the range from 30 to 90; and (c)a softening temperature of greater than 70° C.

In one aspect, an acrylate and/or urethane-containing binder system iscombined with Fe₃O₄to form the magnetic coating of the presentinvention. The ratio of Fe₃O₄: acrylate and/or urethane binder is in therange from 40-70%: 60:30% by weight. The thickness of the magneticcoating may be in the range from 10 mil to 40 mil. Such a magneticcoating exhibits flexibility without any cracking issues.

Following application or inclusion of the magnetic particles into thetextile and/or base component, the particles need to be magnetized.Magnetization can occur either during the curing process or after thecuring process. Curing is typically needed for the binder material thatis selected and/or for the rubber material that may be selected.

During the curing process, the magnetizable particles are mixed with theappropriate binder and applied via a coating technique on the substrateto be magnetized. Once the coating is complete, the particles aremagnetized in the presence of external magnets during the curingprocess. The component that contains the magnetic particles is exposedto a magnetic field which aligns the dipoles of magnetic particles,locking them in place until the binder is cured. The magnetic field ispreferably installed in-line as part of the manufacturing process.However, the magnetic field may exist as a separate entity from the restof the manufacturing equipment.

Alternatively, the magnetic particles may be magnetized after the curingprocess. In this instance, the magnetizable particles are added to thebinder material and applied to the textile and/or base component in theform of a film or coating. The film or coating is then cured. The curedsubstrate is then exposed to at least one permanent magnet. Exposure tothe permanent magnet may be done via direct contact with the coatedsubstrate or via indirect contact with the coated substrate. Directcontact with the permanent magnet may occur, for example, by rolling thepermanent magnet over the coated substrate. The magnet may be rolledover the coated substrate a single time or it may be rolled multipletimes (e.g. 10 times). The permanent magnet may be provided in-line withthe manufacturing process, or it may exist separately from themanufacturing equipment. Indirect contact may include a situationwherein the coated substrate is brought close to the permanent magnet,but does not contact or touch the magnet.

Depending upon the pole size, strength and domains on the permanentmagnet (or electromagnet), it can magnetize the magnetizable coating toa value between 10 and 5000 gauss or a value close to the maximum gaussvalue of the magnetizing medium. Once the coating is magnetized, it willtypically remain permanently magnetized.

It is further contemplated to be within the scope of the presentinvention that the base component of the multi-component floor mat iscomprised of any substance that includes a magnetic material. The basecomponent does not have to be comprised of vulcanized rubber. Instead,the base component may be comprised of concrete, cellulose-containingmaterials (e.g. wood), metal, thermoplastic materials, thermosetmaterials, and the like, and combinations thereof. In one instance, thebase component may be the floor itself where the textile component is tobe installed. Herein, the floor would include at least one magneticmaterial that is used to adhere the textile component to the floor. Thetextile component can then be laid directly on the floor which has atleast one magnetic material applied thereto. Suitable magnetic materialsinclude any of those described previously herein. In one aspect, themagnetic materials may be incorporated into a paint composition andapplied to the floor. Or, an electromagnetic force may be applied to thearea where the textile component is to be installed. Any of thesemagnetic features will provide the necessary adherence of the textilecomponent to the floor without the need for a vulcanized rubber basecomponent.

Floor mats of the present invention may be of any geometric shape orsize as desired for its end-use application. The longitudinal edges ofthe floor mats may be of the same length and width, thus forming asquare shape. Or, the longitudinal edges of the floor mats may havedifferent dimensions such that the width and the length are not thesame. Alternatively, the floor mats may be circular, hexagonal, and thelike. As one non-limiting example, floor mats of the present inventionmay be manufactured into any of the current industry standards sizesthat include 2 feet by 4 feet, 3 feet by 4 feet, 3 feet by 5 feet, 4feet by 6 feet, 3 feet by 10 feet, and the like.

The washable floor mat of the present invention may be exposed to posttreatment steps. For example, chemical treatments such as stain release,stain block, antimicrobial resistance, bleach resistance, and the like,may be added to the washable mat. Mechanical post treatments may includecutting, shearing, and/or napping the surface of the washablemulti-component floor mat.

The performance requirements for commercial matting include a mixture ofwell documented standards and industry known tests. Tuft Bind of PileYarn Floor Coverings (ASTM D1335) is one such performance testreferenced by several organizations (e.g. General ServicesAdministration). Achieving tuft bind values greater than 4 pounds isdesirable, and greater than 5 pounds even more desirable.

Resistance to Delamination of the Secondary Backing of Pile Yarn FloorCovering (ASTM D3936) is another standard test. Achieving Resistance toDelamination values greater than 2 pounds is desirable, and greater than2.5 pounds even more desirable.

Pilling and fuzzing resistance for loop pile (ITTS112) is a performancetest known to the industry and those practiced in the art. The pillingand fuzzing resistance test is typically a predictor of how quickly thecarpet will pill, fuzz and prematurely age over time. The test uses asmall roller covered with the hook part of a hook and loop fastener. Thehook material is Hook 88 from Velcro of Manchester, N.H. and the rollerweight is 2 pounds. The hook-covered wheel is rolled back and forth onthe tufted carpet face with no additional pressure. The carpet is gradedagainst a scale of 1 to 5. A rating of 5 represents no change or newcarpet appearance. A rating of less than 3 typically representsunacceptable wear performance.

An additional performance/wear test includes the Hexapod drum tester(ASTM D-5252 or ISO/TR 10361 Hexapod Tumbler). This test is meant tosimulate repeated foot traffic over time. It has been correlated that a12,000 cycle count is equivalent to ten years of normal use. The test israted on a gray scale of 1 to 5, with a rating after 12,000 cycles of2.5=moderate, 3.0=heavy, and 3.5=severe. Yet another performance/weartest includes the Radiant Panel Test. Some commercial tiles struggle toachieve a Class I rating, as measured by ASTM E 648-06 (average criticalradiant flux >0.45=class I highest rating).

The textile component of the floor mat may be washed or laundered in anindustrial, commercial or residential washing machine. Achieving 200commercial washes on the textile component with no structural failure ispreferred.

The following alignment and deployment techniques may be used forinstalling the multi-component floor mat:

In the first case, it has been found that if the top half is rolled upin a fairly tight roll—face in—and then placed down on the base, thatthe total attraction force is so reduced that an installer can slide theroll enough to be able to get a good alignment with the base using theexposed end of the roll as a guide to align to the base. This method ismainly envisioned for small two part mats. Alignment marks can be put onthe base to assist the top alignment.

The second method is to use the first method but coupled with aremovable temporary “mask” that reduces the attractive force. This canbe accomplished by using film or paper that is placed down on the basebetween the rolled up top and the base only in the area where the rolledup top will touch. Now that the total area is greatly reduced by theroll AND the force per unit area is reduced by the mask, then the easeof moving the roll around to achieve alignment is now even greater. Oncealignment is achieved, the film or paper is slid out.

A third method, that is a refinement of the removable mask method, is touse a mask that is permanently installed and that selectively masks onlythe most critical area—i.e. the area directly below the roll, and leavesthe area near the mat edge alone. For example, if using a magnetic baseand iron containing top, one can use a thin magnetically receptivematerial known as “FlexIron”. This material has the ability tosignificantly reduce the magnetic force while at the same time stronglysticks to the magnetic base and thus will not move; the result is apermanently installed “mask”. This mask is sized and positioned so as toonly mask the magnetic force directly below the roll, but leaves theedges alone so as to keep the force high where the edges must resistkicking up. One still manually aligns the roll and its edge to the base,but now the alignment is relatively easy and can be done quickly.Additionally, the base component can be selectively magnetized so that amasking section is not magnetized. The perimeter around the maskingsection, as well as the perimeter that attracts the edge of the toppiece, can be selectively magnetized.

A fourth method can be used in concert with any of the above methods oralone. This method relies on an alignment pins or grommets that cancapture two or more of the carpet corners. The pins are located ineither the base or top and associated with the pins are complementaryholes in the top or base. Once inserted, the pins capture the other halfof the carpet requiring such that the two halves cannot be separatedwithout substantial force. Once captured, the top mat can be picked upand gently laid down in alignment with the base. If a mat top shouldbecome disturbed or misaligned in the field, it is relatively easy torealign by simply picking the top up and laying it back down. If used inconcert with 1-3 above, alignment now becomes not only easy, but quickand precise. Furthermore if care is taken to ensure that the masked areais always below the alignment pins and is sufficient size so that if thetop is picked up that where it drapes is masked, thenalignment/deployment is always easy.

A fifth method is a refinement of number 4 whereby the attachment pinsare hidden and not visible from the face of the mat top. Methods toaccomplish this are tightly fitting grommets or strong magnets moldedinto or glued to the back of the top mat, or grommets with strongmagnets—all associated with complimentary holes with or without magnetsin the base. This method can also be used in association with any of the1-3 methods.

Another variation includes a line or pattern of magnetic pairs on oneend of the textile component that “snap” the textile component and basecomponent together. These pairs can be spaced such that a singlealignment is highly favorable over any other attraction. The magnetpairs may be arranged with opposing poles and the different pairs in theline or pattern have alternating spacing to prevent misalignment.

EXAMPLES

The invention may be further understood by reference to the followingexamples which are not to be construed as limiting the scope of thepresent invention.

Several variables were tested:

Test Procedures

Commercial Wash Procedure:

1. 140 degree Fahrenheit wash for 10 minutes.

2. 3 rinses, 140 degrees, 3 minutes each.

3. 2 rinses, 90 degrees, 3 minutes each.

4. 2 minutes low extraction.

5. 10 minutes high extraction.

Some samples were evaluated on a “pass” or “fail” basis. A “pass” ratingindicates that the textile component did not fall apart, but rathermaintained its structural integrity and was suitable for use in itsintended purpose. A “fail” rating indicates that one or more layers ofthe textile component came apart, that the textile did not maintain itsstructural integrity, and/or the textile was not suitable for use in itsintended purpose.

Torture Wash:

1. 190 degree Fahrenheit wash for 30 minutes.

2. 2 rinses, 90 degrees, 3 minutes each.

3. 2 minutes low extraction.

4. 10 minutes high extraction.

A Torture Wash is intended to be equivalent to 10 commercial washes.

Lateral Movement Test:

The amount of movement in a floor mat is measured using the lateralmovement test. First a location on the floor is marked usually using apiece of tape. Next a floor mat is placed at that mark. For a lateralmovement walk test, the person conducting the test walks over the testpiece 150 times. Each pass must be in the same direction to ensureaccurate measurement movement. Once this is done 150 times in the samedirection, the person conducting the test must measure how far the testpiece is from the original location. This should be done on both of thefront corners. Once a walk test is completed, a second Lateral MovementCart Test is run. This test involves the same process, but requires acart holding a 100 lb. load to roll over the test piece 50 times. Thedistance is then measured and recorded.

Thickness Determination:

The thickness of each sample was measured using a Starrett pocket dialgauge. The specific model was the Starrett No. 1010. The pocket dialthat was used came with an inspection certificate (Form 804) to ensureaccuracy.

Tuft Lock Test:

The tuft lock test was conducted by cutting out a sample of finishedtextile component approximately 6″×10″. Once the sample was cut out, itwas placed in a TensiTech tensile testing machine. A tensile testingprogram was then run allowing the machine to grasp on to a single tuftin the carpet. Once the machine locked on to a single tuft, it recordedhow much force was required to pull the tuft out of the rubber backedtextile component. This data was then recorded and run 4 more times fora total of 5 pulls. Then, once all tests were complete the data wasevaluated making sure all pulls recorded a value higher than 4.0 lbf.

Body Tear Test:

The body tear test was conducted by cutting out a sample of finishedtextile component approximately 4″×7″ with a 2″ slit at one end of it.Once the sample was cut out, it was placed in a TensiTech tensiletesting machine with one side of the slit in the top clamp, and theother side of the slit in the bottom clamp. A tensile testing programwas then run pulling the top clamp upwards. The force required to pullthe top clamp up was recorded as the sample ripped in half. This datawas then recorded and run 2 more times for a total of 3 pulls. Then,once all tests were complete the data was evaluated making sure allpulls recorded a value higher than 13.0 lbf.

The magnetic hold strength test was conducted by cutting out a 8″×8″sample of finished textile component with smooth magnetically responsivebacking. Once the sample was cut out, it was clamped in the top clamp ofthe Instron tensile testing machine such that the full width of the matwas in the 9 inch wide top clamp to a length of at least 1″ inch. A6″×2″ magnetic strip with a magnetic strength of 200 gauss was mountedon a stiff metal plate measuring 10″×8″ with the long side oriented inthe vertical direction. The metal plate was mounted in an immobilefixture on the base of the machine and aligned parallel to the textilecomponent in such a manner that the magnetic strip was in intimatecontact with the magnetically responsive backing of the finished textilecomponent. A testing program was then run pulling the top clamp upwards.The force required to pull the top clamp up was recorded as the sampletraversed across the length of the magnetic strip. This data was thenrecorded and run 2 more times for a total of 3 pulls. Then once alltests were complete the data was evaluated at 0.1″ traverse to assessthe magnetic hold strength in lbf/inch.

Evaluation of Backing Material

Example 1 Mat with Nitrile Rubber Backing

A mat was prepared as follows:

A tufted face assembly was prepared comprising a nylon 6,6 yarn tuftedinto a pre-shrunk Lutrador 52 nonwoven primary backing. The nylon 6,6yarn was ⅛^(th) inch gauge and was tufted at 8.70 stitches per inch.Tufts were sheared to a pile height of 18/64^(th) inch, resulting in afabric weight of 20.0 oz/sq. yard. The tufted roll measured 145 inchesfrom outside tuft row to outside tuft row.

The tufted roll was then printed using a Millitron® digital printingmachine. The tufted face assembly was run down the Millitron® digitalprinting machine at a speed of 25 feet/minute. A combination of 12 gunbars was utilized to distribute dye to the tufted face assembly with thedye flow set to 36. The tufted face assembly was then exposed to a firststeam step in a steamer at 209° F., and then again in a post steam/stainblocker step at 150° F. The printed tufted face assembly was then driedat 240° F.

The printed tufted face assembly was then slit into 3.2′ wide rolls.These rolls were placed on top of 0.130″ (thickness) nitrile rubber. Theuncured nitrile rubber was then sent into a press with the printedtufted face assembly on top. The press heated up to 365° F. from thebottom as soon as the printed assembly entered the press area. The pressthen applied pressure at 35 psi to the top of the printed tufted faceassembly to push it into the rubber. The printed tufted face assemblywas then held in the press for 8 minutes before it was removed. After itwas removed, it was preshrunk in a drier at 290° F. to form a washablecarpet in roll form. The washable carpet in roll form was then cut intothe desired shape and/or size.

In another example, a mat was made with a 0.030″ thick magneticallyresponsive filler loaded nitrile rubber backing. The mat had solutiondyed yarn (SDN) yarn tufted in a polyester non-woven primary backinglayer. It was bonded to the backing at 370° F. under 35 psi pressure andcured for 4 minutes. No further preshrinking was done. However, thebacking layer was then exposed to a needling process to make it porous.

Evaluation of Backing Style

Smooth Nitrile Backed Mat

A smooth rubber backing has no protrusions on the rubber surface of themat (e.g. the surface of the mat that comes in contact with the magneticbase). In other words, the smooth backing is free from protrusions.Protrusions are typically added to the magnetic base to aid inpreventing unintended lateral movement of the mat.

The construction of the washable mat was identical to the mat producedin Example 1. When the nitrile rubber was placed on the press, it wasput on a Teflon coated belt that had no indentions in it. The top of thebelt was smooth which allowed the bottom of the rubber to have a smoothsurface as well.

Gripper (Standard Cleat) Nitrile Backing for Magnetic Base Component

The nitrile rubber for the base was constructed by layering of themagnetic rubber and the rubber without any magnetic fillers with thelatter one forming the gripper base. A gripper rubber backing wascharacterized by having (1) a grid pattern on the rubber surface thatwas free from protrusions and (2) protrusions on the interior spacesbetween the protrusion free areas. The protrusions were present in asquare pattern. Thus, the gripper backing contained a repeating patternof small protrusions in areas that were ⅞^(ths) inch by 1 inch square.The protrusions were approximately 1/16^(th) inch high. The protrusionscovered approximately 70 percent of the surface of the rubber backing.

The construction of the washable mat was the same as the mat produced inExample 1. When the nitrile rubber was placed on the press, it was puton a Teflon coated belt that had 1/16^(th) inch indention in it in smallsquare patterns. When the press reached 365° F., it caused the rubber tobecome very soft. Once the pressure of 35 psi was applied to the top ofthe washable mat assembly, it pushed the soft rubber into the indentionsforming the “gripper” pattern.

Megahold Nitrile Backing for Magnetic Base Component

The nitrile rubber for the base was constructed by layering of themagnetic rubber and the rubber without any magnetic fillers with thelatter one forming the megahold base. A megahold rubber backing wascharacterized by having fewer and larger indentations on the rubbersurface, when compared to the gripper backing. The indentations werepresent in groups of four that and were spaced in a square pattern.Thus, the megahold pattern contained a repeating pattern of four largeindentations in areas that were 3.625 inches by 3.875 inches square. Theindentations were approximately ⅛ inch deep. The indentations coveredapproximately 40 percent of the surface of the rubber backing.

The construction of the washable mat was the same as the mat produced inExample 1. Before the rubber was placed on to the Teflon belt, theoperator placed a metal plate on the belt. The metal plate containedcircles on the top surface. The circles included a hole drilled in thecenter to allow rubber to form on the inside. The nitrile rubber wasthen placed on top of the metal plate, with the fabric/carpet on top.When the press reached 365° F., it caused the rubber to become verysoft. Once the pressure of 35 psi was applied to the top of the washablemat assembly, it pushed the soft rubber around and into the metal plateforming the “Megahold” backing.

Evaluation of Magnetic Coating Thickness on Textile Component

The magnetic backcoating layer thickness was varied. Samples wereprepared with 20 mils, 25 mils and 30 mils of magnetic backcoating. Thebackcoatings were applied to Forever® mats from Milliken & Company ofSpartanburg, S.C. These mats were then subject to the standard wash andbody tear test and a magnetic shear hold test.

To perform the magnetic shear hold test a test set-up was created wherethe bottom grip of an Instron was replaced by a vertical aluminum platewith a permanent magnet sheet attached. The permanent magnetic sheet wassimilar in construction and in magnetic strength (measured in Gauss) tothe magnetic base component that the magnetic backcoated textilecomponent was installed on. The magnetic backcoated textile componentwas gripped on the top jaw of the test frame such that the magneticbackcoating was attached to the permanent magnet sheet. The assembly wasadjusted to ensure that the backcoated textile component moved parallelto the face of the magnetic sheet on the aluminum plate when the top jawwas moved at a rate of 12 inches/minute. The force on the load cellafter a 1″ traverse was recorded as the magnetic shear force.

The results from testing the backcoated textile at 1×, 10× and 20×torture washes is presented in Table 1 below.

TABLE 1 Evaluation of Magnetic Coating Thickness on Textile ComponentAfter Washing Control Coating Coating Coating mat- Thickness ThicknessThickness 53 mil 30 mil 25 mil 20 mil Mat Units 1X 1X 10X 20X 1X 10X 20X1X 10X 20X Trouser lb 32.6 23.2 23.9 23.9 20.7 24.2 23.7 20.9 23.5 21.9tear force Tuft Lock lb 4.9 4.9 5.0 4.2 5.2 4.9 4.8 4.5 4.2 3.6 forceMagnetic gf — 450.5 350.0 539.0 359.0 160.0 184.0 370.5 94.0 103.5 Hold(Shear)

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the subject matter of this application (especiallyin the context of the following claims) are to be construed to coverboth the singular and the plural, unless otherwise indicated herein orclearly contradicted by context. The terms “comprising,” “having,”“including,” and “containing” are to be construed as open-ended terms(i.e., meaning “including, but not limited to,”) unless otherwise noted.Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the subject matter of theapplication and does not pose a limitation on the scope of the subjectmatter unless otherwise claimed. No language in the specification shouldbe construed as indicating any non-claimed element as essential to thepractice of the subject matter described herein.

Preferred embodiments of the subject matter of this application aredescribed herein, including the best mode known to the inventors forcarrying out the claimed subject matter. Variations of those preferredembodiments may become apparent to those of ordinary skill in the artupon reading the foregoing description. The inventors expect skilledartisans to employ such variations as appropriate, and the inventorsintend for the subject matter described herein to be practiced otherwisethan as specifically described herein. Accordingly, this disclosureincludes all modifications and equivalents of the subject matter recitedin the claims appended hereto as permitted by applicable law. Moreover,any combination of the above-described elements in all possiblevariations thereof is encompassed by the present disclosure unlessotherwise indicated herein or otherwise clearly contradicted by context.

We claim:
 1. A multi-component floor mat comprising: (a) A textilecomponent comprising (i) a first layer of tufted pile carpet formed bytufting face yarns through a primary backing layer and (ii) a secondlayer of vulcanized rubber material that contains magnetic particles;and (b) A base component comprising an elastomer that contains magneticparticles; wherein the textile component and the base component arereleasably attachable to one another via magnetic attraction.
 2. Themulti-component floor mat of claim 1, wherein the textile component ismagnetically receptive.
 3. The multi-component floor mat of claim 1,wherein the base component is permanently magnetized.
 4. Themulti-component floor mat of claim 1, wherein the textile component ofthe floor mat can withstand at least one wash cycle in a commercial orresidential washing machine whereby the textile component is suitablefor re-use after exposure to the at least one wash cycle.
 5. Themulti-component floor mat of claim 1, wherein the face yarns areselected from the group consisting of synthetic fiber, natural fiber,man-made fiber using natural constituents, inorganic fiber, glass fiber,and mixtures thereof
 6. The multi-component floor mat of claim 1,wherein the face yarns are selected from nylon 6; nylon 6,6; polyester;polypropylene; or combinations thereof.
 7. The multi-component floor matof claim 1, wherein the face yarns comprise cut pile, loop pile, orcombinations thereof.
 8. The multi-component floor mat of claim 1,wherein the face yarns are dyed, undyed, printed, or combinationsthereof.
 9. The multi-component floor mat of claim 1, wherein theprimary backing layer is selected from the group consisting of wovenmaterial, nonwoven material, knitted material, and combinations thereof.10. The multi-component floor mat of claim 1, wherein the primarybacking layer is selected from the group consisting of synthetic fiber,natural fiber, man-made fiber using natural constituents, inorganicfiber, glass fiber, and mixtures thereof.
 11. The multi-component floormat of claim 1, wherein the vulcanized rubber is selected from the groupconsisting of nitrile rubber, polyvinyl chloride rubber, ethylenepropylene diene monomer (EPDM) rubber, vinyl rubber, thermoplasticelastomer, and mixtures thereof.
 12. The multi-component floor mat ofclaim 1, wherein the magnet particles are non-degradable.
 13. Themulti-component floor mat of claim 1, wherein the magnetic particles arein an oxidized state.
 14. The multi-component floor mat of claim 1,wherein the magnetic particles are in the size range of from 1 micron to10 microns.
 15. The multi-component floor mat of claim 1, wherein themagnetic particles are magnetizable magnetic particles selected from thegroup consisting of Fe₃O₄, SrFe₃O₄, NdFeB, AINiCo, CoSm and other rareearth metal based alloys, and mixtures thereof.
 16. The multi-componentfloor mat of claim 1, wherein the magnetic particles are magneticallyreceptive particles selected from the group consisting of Fe₂O₃, Fe₃O₄,steel, iron particles, and mixtures thereof.
 17. The multi-componentfloor mat of claim 1, wherein the magnetically receptive particles areparamagnetic or superparamagnetic.
 18. The multi-component floor mat ofclaim 1, wherein the magnetic particle loading is in the range from 10%to 70% by weight in the textile component.
 19. The multi-component floormat of claim 1, wherein the magnetic particle loading is in the rangefrom 10% to 90% by weight in the base component.
 20. The multi-componentfloor mat of claim 1, wherein at least one of the textile and basecomponents is characterized as having a functionally graded magneticparticle distribution.
 21. The multi-component floor mat of claim 1,wherein the magnetic particles are ferrite.
 22. The multi-componentfloor mat of claim 1, wherein the strength of magnetic attraction isgreater than 50 gauss.
 23. The multi-component floor mat of claim 1,wherein the vulcanized rubber contains 0% to 40% recycled rubbermaterial.
 24. The multi-component floor mat of claim 1, wherein theelastomer is selected from the group consisting of natural and syntheticrubber materials, thermoplastic and thermoset resins, and metal.
 25. Themulti-component floor mat of claim 24, wherein natural and syntheticrubber materials are selected from the group consisting of nitrilerubber, polyvinyl chloride rubber, ethylene propylene diene monomer(EPDM) rubber, vinyl rubber, thermoplastic elastomer, and mixturesthereof.
 26. The multi-component floor mat of claim 1, wherein the floormat further includes at least one alignment and deployment mechanism.27. The multi-component floor mat of claim 26, wherein the at least onealignment and deployment mechanism is selected from textile componentconfigurations that reduce surface area, a film material, a sheetingmaterial, and combinations thereof.
 28. The multi-component floor mat ofclaim 1, wherein the floor mat further includes electronic sensors. 29.A multi-component floor mat comprising: (a) A textile componentcomprising (i) tufted pile carpet wherein face yarns are tufted througha primary backing layer and (ii) a magnetic coating wherein the magneticcoating is comprised of magnetic particles and a binder material; and(b) A base component comprising an elastomer that contains magneticparticles; wherein the textile component and the base component arereleasably attachable to one another via magnetic attraction.
 30. Themulti-component floor mat of claim 29, wherein the binder material isselected from a thermoplastic elastomer material, a thermoplasticvulcanite material, and mixtures thereof.
 31. The multi-component floormat of claim 30, wherein the binder material is selected from the groupconsisting of urethane-containing materials, acrylate-containingmaterials, silicone-containing materials, and mixtures thereof.
 32. Themulti-component floor mat of claim 29, wherein the magnetic coating isapplied to the textile component via knife coating, pad coating, paintcoating, spray application, roll-on-roll methods, troweling methods,extrusion coating, foam coating, pattern coating, print coating,lamination, and mixtures thereof.
 33. The multi-component floor mat ofclaim 29, wherein the elastomer is selected from the group consisting ofnatural and synthetic rubber materials, thermoplastic and thermosetresins, and metal.
 34. The multi-component floor mat of claim 33,wherein natural and synthetic rubber materials are selected from thegroup consisting of nitrile rubber, polyvinyl chloride rubber, ethylenepropylene diene monomer (EPDM) rubber, vinyl rubber, thermoplasticelastomer, and mixtures thereof.
 35. The multi-component floor mat ofclaim 29, wherein the floor mat further includes at least one alignmentand deployment mechanism.
 36. The multi-component floor mat of claim 35,wherein the at least one alignment and deployment mechanism is selectedfrom textile component configurations that reduce surface area, a filmmaterial, a sheeting material, and combinations thereof.
 37. Themulti-component floor mat of claim 29, wherein the floor mat furtherincludes electronic sensors.
 38. A process for cleaning amulti-component floor mat, said process comprising the steps of: (a)Providing the multi-component floor mat of claim 1; (b) Removing thetextile component from the base component; (c) Laundering the textilecomponent in an industrial, commercial, or residential washing machine;and (d) Re-installing the textile component on or within the basecomponent.
 39. A process for making a multi-component floor mat, saidprocess comprising the steps of: (a) Tufting face yarns into a primarybacking material to form a tufted pile carpet; (b) Optionally, printingthe tufted pile carpet; (c) Providing a layer of unvulcanized rubberthat contains magnetic particles; (d) Adhering the tufted pile carpet tothe layer of magnetic particle-containing unvulcanized rubber via arubber vulcanization process to form a washable textile component havinga vulcanized rubber backing; (e) Cutting the textile component into adesired shape and size; (f) Providing a base component comprised of anelastomer that contains magnetic particles; and (g) Attaching thetextile component to the base component via magnetic attraction.
 40. Aprocess for making a multi-component floor mat, said process comprisingthe steps of: (a) Tufting face yarns into a primary backing material toform a tufted pile carpet; (b) Optionally, printing the tufted pilecarpet; (c) Providing a magnetic coating comprised of magnetic particlesand a binder material; (d) Adhering the magnetic coating to the tuftedpile carpet to form a washable textile component; (e) Cutting thetextile component into a desired shape and size; (f) Providing a basecomponent comprised of an elastomer that contains magnetic particles;and (g) Attaching the textile component to the base component viamagnetic attraction.